What Is Virtual Commissioning (VIBN)?
Virtual commissioning means testing an automation system completely in a simulation environment before a single bolt is turned on real hardware. This sounds like a luxury — but in many industries it has long been standard practice. Automotive, pharma, and aerospace have used virtual commissioning for years. In general machine building it is still underutilized — an expensive oversight.
The Real Costs Without Simulation
Consider a typical robot handling system: on-site commissioning at the customer, 3 engineers, 3 weeks planned. What actually happens:
- Week 1: Mechanics not finished yet, PLC program has coordination errors
- Week 2: Robot program collides with guarding, cycle time missed
- Week 3: Troubleshooting, customer pressure, night shifts
- Week 4 (unplanned): Rework, delayed acceptance
Additional costs: 40–80% of the original commissioning budget. This is not an exception — it is the norm for systems developed without virtual commissioning.
Key Virtual Commissioning Tools
KUKA.Sim Pro
The native simulation tool for KUKA robots. It enables complete kinematic simulation including collision detection, cycle time measurement, and reachability analysis. Particularly valuable: KUKA.Sim Pro works directly with KRL code and exports programs that run on the real KRC4 without modification. A connection to SIMIT can also be established to test the PLC program simultaneously.
ABB RobotStudio
RobotStudio is the reference tool for ABB robots. The "Virtual Controller" technology is identical to the real IRC5 controller — RAPID code that works in RobotStudio runs on the real robot. The integrated I/O simulation enables connection to external simulators. RobotStudio also supports MultiMove applications (multiple cooperating robots).
Siemens SIMIT
SIMIT is the Siemens simulation platform for PLC programs. The software emulates field devices (drives, sensors, actuators) and communicates directly with TIA Portal via PROFINET or PLCSIM Advanced. This allows the complete PLC program to be tested without a single real I/O. SIMIT libraries for standard devices (Siemens drives, valves) significantly reduce modeling effort.
Process Simulate (formerly Tecnomatix)
Siemens Process Simulate is the most comprehensive tool for complete production lines. It integrates robots from various manufacturers, conveyor technology, manufacturing operations, and enables digital twin approaches at factory level. Connection to MES and ERP systems is possible.
ROI Calculation: Concrete Numbers
A real project from our experience: automotive supplier, robot welding line, 4 KUKA robots, 2 PLC systems.
Without virtual commissioning (historical comparison):
- Commissioning planned: 4 weeks, 3 engineers = 60 person-days
- Actual: 7 weeks, 4 engineers = 140 person-days
- Additional travel costs, machine downtime at customer: ~€80,000
With virtual commissioning (same system, one year later):
- VIBN phase: 3 weeks (office), 2 engineers = 30 person-days
- On-site commissioning: 2.5 weeks, 2 engineers = 25 person-days
- Total savings: ~55 person-days + €60,000 in avoided overruns
At a day rate of €1,200, this represents savings of approximately €66,000 on a single project. Virtual commissioning tools typically cost €15,000–30,000 per year (licenses). The investment pays off by the second project.
Time Savings: The 30–50% Rule
Industry studies (including from Fraunhofer IPA and Siemens) consistently show: virtual commissioning reduces on-site commissioning time by 30–50%. The key levers:
- Find errors early: Fixing collisions and logic errors in the office is 10× cheaper than on-site
- Parallelization: While mechanics are still being built, software development runs in the simulator
- Training: Operators can train on the simulation before the system exists
- Documentation: Simulation models simultaneously serve as documentation and training material
Digital Twin: From Virtual Commissioning to Ongoing Value
Virtual commissioning is not a one-time benefit. The simulation model can be maintained as a digital twin:
- Test new programs in simulation before going live
- Reproduce causes of system problems in the simulation
- Try out cycle time optimizations in the simulator
- Maintenance training without machine downtime
The key is keeping the model current after commissioning. Changes to the real system must be mirrored in the simulation model.
Integration with TIA Portal
The SIMIT–TIA Portal integration is seamless today. Via PLCSIM Advanced V4.0, you can run the S7-1500 program as a software PLC on a PC and communicate with the SIMIT model over standard PROFINET. The setup requires:
- TIA Portal V17+ with PLCSIM Advanced
- SIMIT V10.2+
- A network configuration in SIMIT emulating the physical PROFINET devices
In this configuration, the complete PLC program runs exactly as on real hardware — with the difference that all I/Os are simulated.
Conclusion: When Virtual Commissioning Isn't Worth It
Virtual commissioning is not a silver bullet. For very simple systems (fewer than 5 I/O modules, one robot, proven code), the modeling effort may exceed the benefit. The entry barrier — licenses, learning curve, modeling skills — is real. But: those who have used virtual commissioning professionally once do not return to purely real commissioning. The advantages in quality, deadlines, and stress are too great.